Modular head restraint structure and styling enablement features

ABSTRACT

A headrest assembly for a vehicle seat includes a front panel with a base portion and a support portion. A rear panel includes a base portion and a support portion. A support member includes first and second legs that are interconnected by an upper cross member. First and second support wings are coupled to the first and second legs of the support member and outwardly extend therefrom. The base portion of the front panel couples to a front side of the first and second support wings. The base portion of the rear panel couples to a rear side of the first and second support wings. The support wings are overmolded to the support member along with one or more attachment features to interconnect the front and rear panels to one another around the support member.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.15/398,855 (now U.S. Pat. No. 10,106,068), filed on Jan. 5, 2017,entitled MODULAR HEAD RESTRAINT STRUCTURE AND STYLING ENABLEMENTFEATURES, the entire disclosure of which is hereby incorporated byreference.

FIELD OF THE INVENTION

The present invention generally relates to a vehicle seating assembly,and more particularly, to a vehicle seating assembly configured for highperformance vehicles having specific weight and support requirements,wherein a head restraint assembly is adjustable to accommodate specificperformance conditions, and further wherein the seatback includes animproved entry system as opposed to a fully rigid racing seat.

BACKGROUND OF THE INVENTION

In high performance vehicles, seat assemblies are configured to offersufficient support and rigidity for keeping a vehicle occupant safelypositioned within the seat assembly. Further, seat assemblies in highperformance vehicles are often configured to provide the necessarysupport for a vehicle occupant while also being an overall light weightseat assembly to accommodate weight considerations for a highperformance vehicle. While the seat assembly of a high performancevehicle must include the structural and support features necessary tokeep a vehicle occupant safe, a need also exists to provide comfort andconvenience features in high performance vehicles that may also beconsidered daily drivers. Thus, a headrest assembly having adjustabilityfeatures for accommodating specific race day requirements (i.e.,helmets) and seatbacks that provide improved access to rear seats aredesired.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a headrest assemblyfor a vehicle seat having a front panel with a base portion and asupport portion. A rear panel includes a base portion and a supportportion. A support member includes first and second legs that areinterconnected by an upper cross member. First and second support wingsare coupled to the first and second legs of the support member andoutwardly extend therefrom. The base portion of the front panel couplesto a front side of the first and second support wings. The base portionof the rear panel couples to a rear side of the first and second supportwings.

According to another aspect of the present invention, a headrestassembly having a support member with first and second support wingsoutwardly extending from opposite sides of the support member. A frontpanel includes a base portion coupled to the first and second supportwings. A rear panel includes a base portion coupled to the first andsecond support wings, wherein the rear panel is further coupled to thefront panel to surround the support member.

According to yet another aspect of the present invention, a headrestassembly having a support member. First and second support wingsoutwardly extend from opposite sides of the support member. The firstand second support wings included a plurality of channels disposedthereon. A front panel includes a base portion having a plurality ofsupport ribs. One or more of the support ribs of the font panel arereceived in one or more of the channels disposed on the first and secondsupport wings. A rear panel includes a base portion. The base portion ofthe rear panel includes a plurality of support ribs. One or more of thesupport ribs of the rear panel are received in one or more of thechannels disposed on the first and second support wings.

These and other aspects, objects, and features of the present inventionwill be understood and appreciated by those skilled in the art uponstudying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a front perspective view of a vehicle seat assembly accordingto one embodiment of the present invention;

FIG. 2 is a rear perspective view of the vehicle seat assembly of FIG.1;

FIG. 3 is a front perspective view of internal frame components of thevehicle seat assembly of FIG. 1;

FIG. 4A is a front perspective view of a seatback frame assembly havinga seatback frame adjustment system;

FIG. 4B is a rear perspective view of the seatback frame assembly ofFIG. 4A;

FIG. 5A is a close-up view of a first actuator taken at location VA ofFIG. 4B;

FIG. 5B is a side elevational view of the first actuator of FIG. 5A;

FIG. 5C is a fragmentary front perspective view of an upper portion ofthe seatback frame assembly of FIG. 4A showing an actuator housing;

FIG. 6A is a front elevational view of the actuator housing of FIG. 5Cwith a cover member removed to reveal a second actuator shown in anat-rest position;

FIG. 6B is a front elevational view of the second actuator of FIG. 6A inan actuated position;

FIG. 6C is a top perspective view of the second actuator exploded awayfrom a base plate of the actuator housing of FIG. 6B;

FIG. 6D is a rear perspective view of the base plate of FIG. 6C;

FIG. 6E is an exploded top perspective view of an actuator housingaccording to another embodiment;

FIG. 6F is an exploded rear perspective view of the actuator housing ofFIG. 6E;

FIG. 6H is a fragmentary front perspective view of another embodiment ofa first actuator coupled to a seatback frame;

FIG. 6G is a side elevational view of the first actuator of FIG. 6H;

FIG. 7 is a fragmentary top perspective view of a recliner mechanismcoupled to the seatback frame of FIG. 4A taken at location VII;

FIG. 8A is an exploded front perspective view of a headrest assembly;

FIG. 8B is an exploded rear perspective view of the headrest assembly ofFIG. 8A;

FIG. 9A is a front perspective view of a support member for a headrestassembly;

FIG. 9B is a rear perspective view of the support member of FIG. 9A;

FIG. 10A is a rear perspective view of a front panel for a headrestassembly;

FIG. 10B is a front perspective view of a rear panel for a headrestassembly;

FIG. 11A is an exploded front perspective view of a headrest assemblyaccording to another embodiment;

FIG. 11B is an exploded rear perspective view of the headrest assemblyof FIG. 11A;

FIG. 12A is a front perspective view of a receiving block having detentengagement features exploded away therefrom;

FIG. 12B is a rear perspective view of a headrest bun having a mountingsurface with an interlock member extending outwardly therefrom;

FIG. 12C is a front perspective view of a headrest assembly according toanother embodiment having the receiving block of FIG. 12A and theheadrest bun of FIG. 12B exploded away therefrom;

FIG. 12D is a front perspective view of the headrest assembly of FIG.12C showing the headrest bun coupled thereto in phantom of FIG. 12B;

FIG. 13A is a front perspective view of a headrest assembly according toanother embodiment;

FIG. 13B is a front perspective view of the headrest assembly of FIG.13A having a headrest bun exploded away therefrom;

FIG. 13C is a rear perspective view of the headrest assembly of FIG. 13Bwith the headrest bun coupled thereto; and

FIG. 13D is a front perspective view of the headrest assembly of FIG.13C.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

For purposes of description herein, the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the disclosure as oriented in FIG. 1. However,it is to be understood that the disclosure may assume variousalternative orientations, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings, and described in thefollowing specification are simply exemplary embodiments of theinventive concepts defined in the appended claims. Hence, specificdimensions and other physical characteristics relating to theembodiments disclosed herein are not to be considered as limiting,unless the claims expressly state otherwise.

Referring now to FIG. 1, the reference numeral 10 generally indicates avehicle seat assembly. The vehicle seat assembly 10 shown in FIG. 1 is ahighly contoured and stylized seat assembly that is configured for usein a high performance vehicle. The vehicle seat assembly 10 generallyincludes a seat member 12 which is supported on a track system 14 forlinear movement between fore and aft positions. The vehicle seat 10further includes a seatback 16 which is contemplated to be pivotallycoupled to the seat member 12. The seatback 16 is contemplated to movebetween various positions along the path as indicated by arrow 18between a full forward position F and a reclined position R. In FIG. 1,the seatback 16 is generally shown in an upright use position forproperly supporting a vehicle occupant. The seat assembly 10 furtherincludes a headrest assembly 20 having a base portion 22 and a supportportion 24 which includes a cushioned headrest bun 26. The base portion22 of the headrest assembly 20 further includes a thoracic supportcushion 28 disposed on a front portion thereof. The headrest assembly 20is designed to provide a robust support system for the head of a vehicleoccupant as desired for use in a high performance vehicle where avehicle occupant is subject to more intense forces as compared to aregular automotive vehicle given the speed, performance, and handlingassociated with a high performance vehicle.

To provide the enhanced support features desired in a high performancevehicle, the seat assembly 10 includes the robust headrest assembly 20having a forwardly curved base portion 22 that has a width commensuratewith a width of the seatback 16. The seatback 16 includes first andsecond side bolsters 16A, 16B disposed on opposite sides of an insetcentral portion 16C. The seat member 12 similarly includes first andsecond side bolters 12A, 12B which outwardly extend from a generallyinset central portion 12C. With the first and second side bolsters 16A,16B of the seatback 16 and the first and second side bolsters 12A, 12Bof the seat member 12, the central portions 12C, 16C of the seat member12 and seatback 16 generally define a bucket seat configuration for thevehicle seat assembly 10. The first and second side bolsters 12A, 12B,16A, 16B are generally configured to properly position and support,retain a vehicle occupant while driving a high performance vehicle.

Referring now to FIG. 2, the vehicle seat assembly 10 is shown from arear perspective view, wherein a pivot access PA is indicated formovement of the seatback 16 relative to the seat member 12. As notedabove, the seatback 16 is configured for movement between forward andrear positions F, R along the path as indicated by arrow 18. In FIG. 2,the seatback 16 is shown in an upright use position for supporting avehicle occupant. The vehicle seat assembly 10 of the present inventionincludes a convenience feature for using the vehicle seat assembly 10 ina high performance vehicle that may also include a rear seating option.To this end, the vehicle seat assembly 10 includes an easy entry systemwhich provides free movement of the seatback 16 to a full forwardposition F, wherein the seatback 16 is rotated forward towards the seatmember 12 to provide access to a rear seating option. The full forwardposition may also be referred to as a forward dump position or an easyentry position. Rotation of the seatback 16 relative to the seat member12 is provided along the pivot access PA along the rotational path asindicated by arrow 18. In the rear perspective view of FIG. 2, theseatback 16 is shown having a first actuator 30 disposed thereon. Thefirst actuator 30 is operable between at-rest and actuated positions, asfurther described below, and is configured to release the seatback 16for movement to the full forward position F when the first actuator 30is moved to the actuated position. As shown in FIG. 2, the firstactuator 30 is an exterior actuator accessible from a rear side of theseatback 16.

Referring now to FIG. 3, a frame assembly 32 is shown having a seatmember frame 34 coupled to the track assembly 14. The seat member frame34 includes first and second side members 36, 38 which areinterconnected by front and rear cross members 40, 42. The frameassembly 32 further includes a seatback frame 50 having first and secondside members 52, 54 which are interconnected by upper and lower crossmembers 56, 58. The first and second side members 52, 54 include upperportions 52A, 54A and lower portions 52B, 54B. The upper portions 52A,54A of the first and second side members 52, 54 are coupled to the uppercross member 56, while the lower portions 52B, 54B of the first andsecond members 52, 54 are coupled to the lower cross member 54. Thelower portions 52B, 54B of the first and second side members 52, 54 arefurther coupled to the side members 36, 38 of the seat member frame 34in a pivoting manner, such that the seatback frame 50 is configured topivot along the pivot access PA along the path as indicated by arrow 18.As the frame assembly 32 is configured to support the seat member 12 andseatback 16 of the vehicle seat 10 shown in FIG. 1, one of ordinaryskill in the art will appreciate that movement of the seatback frameassembly 50 correlates to movement of the seatback 16 as describedthroughout the present disclosure.

As further shown in FIG. 3, the first actuator 30 is shown mounted tothe second side member 54 of the seatback frame 50 at the upper portion54A of the second side member 54. While the first actuator 30 is shownconveniently located at this position on the second side member 54, itis contemplated that the first actuator 30 may be disposed on anyportion of the frame assembly 32 that is readily accessible by a userfor adjusting a position of the seatback frame 50. Movement of theseatback frame 50 to the full forward position F is generally providedby the release of a recliner mechanism coupled between the seatbackframe 50 and seat member frame 34, as further described below.

As further shown in FIG. 3, the upper cross member 56 of the seatbackframe 50 includes upper and lower portions 56A, 56B, wherein the upperportion 56A includes receiving apertures 62, 64 which are configured toreceive guide sleeves for supporting the headrest assembly 20 (FIG. 1)from the upper cross member 56 of the seatback frame 50. The upperportion 56A further includes mounting aperture 57 which is configured toreceive a mounting structure 330 (FIG. 10D) of the headrest assembly 20for supporting the headrest assembly 20 from the upper cross member 56of the seatback frame 50. The lower portion 56B of the upper crossmember 56 includes an actuator housing 70 coupled to a front sidethereof. The actuator housing 70 is configured to house a secondactuator as further described below. In the embodiment shown in FIG. 3,the actuator housing 70 includes first and second cables 72, 74connected thereto. The first cable 72 is shown directed towards thesecond side member 54 of the seatback frame 50 and couples to the firstactuator 30 in assembly, as further described below. The second cable 74is shown coupled to the actuator housing 70 on an opposite side thereofrelative to the first cable 72, wherein the second cable 74 is alsodirected towards the second side member 54 of the seatback frame 50 forcoupling to a recliner mechanism, as further described below. With thefirst and second cables 72, 74 shown directed to the second side member54 of the seatback frame 50, and having the first actuator 30 supportedby the second side member 54 of the seatback frame 50, it iscontemplated that the vehicle seat 10 (FIG. 1) is a driver's side seatassembly, wherein the second side members 54, 38 of the frame assembly32 are the outer side members generally made accessible to a user when adriver's side door is open. However, it is contemplated that theconcepts disclosed herein are not limited to a driver's side seatassembly, and may be used in conjunction with any seat assemblypositioned within an interior of a vehicle.

Referring now to FIG. 4A, the seatback frame 50 is shown with firstcable 72 having a second end 72B coupled to an upper portion of theactuator housing 70. Second cable 74 is shown having a first end 74Acoupled to a lower portion of the actuator housing 70 on an oppositeside of the actuator housing 70 relative to the attachment of the secondend 72B of the first cable 72. As further shown in FIG. 4A, the secondcable 74 further includes a second end 74B that is coupled to a reclinermechanism 80. The recliner mechanism 80 is contemplated to be a standardrecliner mechanism known in the art for retaining the seatback frame 50in an upright use position, such as the position of the seatback 16shown in FIG. 1. The recliner mechanism 80 is configured to provide areclining feature for the seatback 16 along the path as indicated byarrow 18. The recliner mechanism 80 is also used to release the seatbackframe 50 for free movement along the path as indicated by arrow 18 tothe full forward position F as indicated in FIG. 1. Thus, the reclinermechanism 80 is operable between locked and release positions, whereinthe seatback frame 50 moves freely relative to the seat member 12 whenthe recliner mechanism 80 is in the release position. The reclinermechanism 80 is moved to the release position when the first actuator 30is moved from an at-rest position to an actuated position, as furtherdescribed below. Connection of the second end 74B of the second cable 74to the recliner mechanism 80 is best shown and described below withspecific reference to FIG. 7.

Referring now to FIG. 4B, the first cable 72 is shown having a first end72A which is operably couple to the first actuator 30 which is furthercoupled to second side member 54 of the seatback frame 50. The uppercross member 56 of the seatback frame 50 is shown having a mountingaperture 56 disposed on the lower portion 56B thereof. The mountingaperture 56 is shown in FIG. 4B as having first and second hook members77, 78 extending therethrough, wherein the first and second hook members77, 78 rearwardly extend from the actuator housing 70 to couple theactuator housing 70 to the mounting aperture 76 of the upper crossmember 56 of the seatback frame 50.

Referring now to FIG. 5, the first actuator 30 is shown in the form of astrap extending outwardly from a receiving aperture 82 of a trimcomponent 84. The trim component 84 is configured to couple to a rearportion of the seatback 16 as shown in FIG. 2 while the actuator 30extends outwardly therefrom through receiving aperture 82. A supportbracket 86 is shown coupled to second side member 54 of the seatbackframe 50 and includes an upper end 86A coupled to trim component 84, anda lower end 86B coupled to first cable 72. First end 72A of the firstcable 72 is coupled to the first actuator 30 at a coupling portion 30Bthereof, as best shown in FIG. 5B. The first actuator 30 includes ahandle portion 30A and a coupling portion 30B (FIG. 5B), wherein thehandle portion 30A outwardly extends from the seatback 16 of the vehicleseat assembly 10 (as shown in FIG. 2), such that the first actuator 30is easily accessed by a user. As noted above, the first actuator 30 maybe a strap member which may include a loop portion for better engagementby a user at the handle portion 30A, or may include any type ofrubberized grip portion disposed on the handle portion 30A.

Referring now to FIG. 5B, the first actuator 30 is shown in an actuatedposition, wherein the handle portion 30A of the actuator 30 iscontemplated to have been pulled upwardly and outwardly in a directionas indicated by arrow 90 from an at-rest position towards the actuatedposition. When moving the first actuator 30 from the at-rest position tothe actuated position (shown in FIG. 5B), the first end 72A of cable 72travels a first distance D1 as indicated in FIG. 5B. Specifically, thefirst end 72A of first cable 72 is shown in phantom at reference numeral72A1 which correlates to the position of the first end 72A when thefirst actuator 30 is in the at-rest position. With the actuator 30 inthe actuated position shown in FIG. 5B, the first end 72A of first cable72 is contemplated to move from the position indicated at 72A1, to theposition indicated at 72A2. This movement of the first cable 72 is equalto a first distance D1 which is approximately 43-44 mm. As further shownin FIG. 5B, mounting bracket 86 is coupled to the second side member 54of the seatback frame 50 and is coupled to the trim component 84 housingthe first actuator 30 at an upper end 86A thereof. At a lower end 86B ofthe mounting bracket 86, a cap 92 of the first cable 72 is shownretained thereon. The cap 92 is disposed over an end of a cable housing94 of the first cable 72 which generally protects the first cable 72 aspositioned within the vehicle seat assembly 10. Thus, as shown in FIG.5B, the actuation stroke of the first actuator 30 is an upward andoutward movement in the direction as indicated by arrow 90 that isapproximately 43-44 mm, however, other lengths for an actuator stroke ofthe first actuator 30 are also contemplated. With the coupling portion30B of the first actuator 30 being coupled to the first end 72A of thefirst cable 72, the movement or travel of the first cable 72 isgenerally equal to the movement of the first actuator 30 from theat-rest position to the actuated position, such that the first distanceD1 of travel of the first cable 72 is contemplated to be approximately43-44 mm like the actuation stroke of the first actuator 30.

Referring now to FIG. 5C, the actuator housing 70 is shown coupled tothe lower portion 56B of the upper cross member 56 of the seatback frame50. The actuator housing 70 includes a cover member 100 coupled to abase plate 102 by fasteners 104 to define a cavity 106 disposed betweenthe cover member 100 and base plate 102. As further shown in FIG. 5C,the second end 72B of first cable 72 feeds into the cavity 106 of theactuator housing 70, while first end 74A of the second cable 74 feedsinto the cavity 106 of the actuator housing 70 on an opposite sidethereof relative to the first cable 72. The first and second cables 72,74 each include cable housings 94 and are operably coupled to a secondactuator housed within the actuator housing 70 for movement therewith,which will now be described.

Referring now to FIG. 6A, the base plate 102 of the actuator housing 70is shown having a rear surface 110 with an outwardly extending perimeterportion 112 disposed therearound. The outwardly extending perimeterportion 112 includes first and second side members 112A, 112B disposedon opposite sides of the base plate 102. Each of the first and secondside members 112A, 112B include upper and lower access apertures 114,116. The first cable 72 enters the cavity 106 of the actuator housing 70at the upper access aperture 114 disposed through side member 112A. Thesecond cable 74 accesses the cavity 106 of the actuator housing 70 atlower access aperture 116 of side member 112B. As further shown in FIG.6A, a second actuator 120 is disposed within the cavity 106 of theactuator housing 70 for movement along a path as indicated by arrow 121between at-rest and actuated positions. In the embodiment shown in FIG.6A, the second actuator 120 is shown in the at-rest position. The secondactuator 120 includes upper and lower portions 122, 124 with anintermediate portion 126 disposed therebetween. As shown in FIG. 6A, thelower portion 124 is pivotally coupled to the base plate 102 at fastener128, thereby defining a pivot point 129 for the second actuator 120relative to the base plate 102. The second end 72B of the first cable 72is shown coupled to a first mounting aperture 130A disposed at the upperportion 122 of the second actuator 120. The first end 74A of the secondcable 74 is shown coupled to a second mounting aperture 130B disposed atthe intermediate portion 126 of the second actuator 120. In this way,the first cable 72 is coupled to an upper portion 122 of the secondactuator 120, while the second cable 74 is coupled to an intermediateportion 126 of the second actuator 120. The first and second mountingapertures 130A, 130B of the second actuator 120 are spaced-apart fromone another at difference distances relative to the central pivot point129, thereby affecting the length of cable pulled when the secondactuator 120 is moved between the at-rest position and the actuatedposition.

With specific reference to FIG. 6B, the distance of the first mountingaperture 130A from the pivot point 129 is represented by a firstdistance 1D (contemplated to be approximately 56 mm). The distance ofthe second mounting aperture 130B from the pivot point 129 isrepresented as a second distance 2D (contemplated to be approximately 25mm). Thus, as shown in FIG. 6B, the first distance 1D of the pivot point129 to the first mounting aperture 130A is greater than the seconddistance 2D disposed between the pivot point 129 and the second mountingaperture 130B. In fact, the first distance 1D is more than double thesecond distance 2D. This is generally due to the illustratedconfiguration wherein the first mounting aperture 130A is disposed atthe upper portion 122 of the second actuator 120, while the secondmounting aperture 130B is disposed at the intermediate portion 126 ofthe second actuator 120. This variance in distance between first andsecond distances 1D, 2D correlates to a reduced length of travel for thesecond cable 74 as compared to a distance traveled by the first cable 72during an actuation sequence.

With further reference to FIG. 6B, the second end 72B of the first cable72 is coupled to the upper portion 122 of the second actuator 120 atfirst mounting aperture 130A. As noted above, with reference to FIGS. 5Aand 5B, the first end 72A of the first cable 72 is coupled to the firstactuator 30 at coupling portion 30B. Thus, when the first actuator 30 ismoved to the actuated position (FIG. 5B), the second actuator 120 movesfrom the at-rest position (FIG. 6A) to the actuated position (FIG. 6B).This distance generally correlates to the first distance D1 of travelfor the first cable 72 at the first actuator 30. Thus, the distancetraveled by the second end 72B of the first cable 72 as coupled tomounting aperture 130A of second actuator 120 from the at-rest positionto the actuated position is approximately 43-44 mm. As a corollary, thefirst end 74A of second cable 74 will move approximately 20 mm from theposition of the first end 74A shown in FIG. 6A to the position of thesecond end at 74A shown in FIG. 6B. This is due to the intermediatelocation of the second mounting aperture 130B on the second actuator120. Thus, the movement of the first actuator 30 draws the first end 72Aof the first cable 72 upward, which translates to a lateral pull of thefirst cable 72 at second end 72B as coupled to the second actuator 120.This makes the movement of the first cable 72 an input movement on thesecond actuator 120. Movement of the second actuator 120 from theat-rest position (FIG. 6A) to the actuated position (FIG. 6B) causes thefirst end at 74A of second cable 74 to move approximately 20 mm inresponse to the input action by the first cable 72. As such, themovement of the second cable 74 is an output movement which translatesto a release of the recliner mechanism 80 as further described belowwith reference to FIG. 7. Thus, the movement of the second cable 74 inresponse to the input movement of the first cable 72 is less than halfthe distance traveled by the first cable 72.

As further shown in FIG. 6B, the second actuator 120 may also movebeyond the actuated position shown in FIG. 6B to a range identified byreference numeral 132 which indicates an over-travel position for thesecond actuator 120. From the actuated position shown in FIG. 6B to thefull range of the over-travel position 132, the first cable 72 iscontemplated to move approximately 70 mm. Similarly, with the secondactuator 120 moved to the full over-travel position identified in therange 132, the second cable 74 will travel approximately 29 mm. In thisway the second actuator 120 operates between the at-rest position shownin FIG. 6A to the actuated position shown in FIG. 6B with a traveldistance of approximately 45 mm. The second actuator 120 can furthermove approximately another 15 mm to the full over-travel position toensure that the necessary amount of cable travel for the second cable 74will occur to sufficiently cause the release of the recliner mechanism80 (FIG. 7).

As further shown in FIG. 6B, the rear surface 110 of the base plate 102includes first and second raised guide rails 134, 136 which areconfigured to guide the movement of the second actuator 120 in a lowfriction manner between at-rest, actuated, and over-travel positions.Each of the first and second raised guide rails 134, 136 include firstand second abutment members 138 disposed at opposite ends thereof forlimiting movement of the second actuator 120 beyond the over-travelposition and at the at-rest position by abutting opposite side surfaces139A, 139B of the second actuator 120. Further, it is contemplated thatthe second actuator 120 is biased to the at-rest position by a biasingmechanism disposed along the adjustment assembly.

Referring now to FIG. 6C, the second actuator 120 is shown exploded awayfrom the base plate 102 and it is shown having a receiving aperture 140disposed therethrough at the lower portion 124 of the second actuator120. The receiving aperture 140 is configured to receive the fastener128 which couples to the base plate 102 for pivotal movement of thesecond actuator 120. The second actuator 120 further includes a steppedguide 142 which aligns to an arched guide 144 of the base plate 102 toguide movement of the second actuator 120 in an arcuate manner. Thesecond actuator 120 further includes a rear surface 146 which isconfigured to contact the raised guide rails 134, 136 of the base plate102 in assembly for sliding movement of the second actuator 120 thereon.As further shown in FIG. 6, the first and second mounting apertures130A, 130B include access slots 148, 150 which are used to guide thefirst and second cables 72, 74 into their respective mounting apertures130A, 130B. As further shown in FIG. 6C, the second end 72B of firstcable 72 includes an engagement member 152 in the form of a barrel whichis received in the mounting aperture 130A, while the first cable 72 isthreaded through the access slot 148 of the second actuator 120 whenmounting the first cable 72 to the second actuator 120. Similarly, abarrel 152 disposed on the first end 74A of second cable 74 is receivedin mounting aperture 130B of second actuator 120 while the second cable74 is threaded through access slot 150 of the second actuator 120.

Referring now to FIG. 6D, an outer surface 154 of the base plate 102 isshown disposed on an opposite side of the base plate 102 relative to therear surface 110 and includes the first and second hook members 77, 78which are used to couple and support the actuator housing 70 to theupper cross member 56 of the seatback frame as best shown in FIG. 4B.

Referring now to FIGS. 6E and 6F, another embodiment of an actuatorhousing 70A is shown which includes a number of features which aresimilar to features found in the actuator housing 70 described above,for which like reference numerals will be used. The cover member 100 ofthe actuator housing 70A is shown exploded away from a base plate 102,wherein the base plate 102 includes a plurality of engagement features160 disposed around a perimeter thereof in the form of resilient springfinger clips. Accordingly, the cover member 100 includes a plurality ofengagement features 162 extending off a perimeter thereof which areshown in the form of U-shaped receptacles configured to receive theclips of the engagement features 160 of the base plate 102. In this way,the cover member 100 can clip to the base plate 102 to define thehousing 106 in which the second actuator 120 moves without the need forseparate fasteners. Further, with specific reference to FIG. 6F, theouter surface 154 of the base plate 102 includes resilient clip members164 which can be used to releasably clip the base plate 102 to the uppercross member 56 of the seatback frame assembly 50 for securing theactuator housing 70A thereto.

Referring now to FIG. 6H, another embodiment of the first actuator 170is shown disposed within a trim component 172 which couples to thesecond side member 54 of the seatback frame 50 using one or moreresilient clip members 174, as well as an upper engagement feature 176.In assembly, it is contemplated that the trim component 172 ispositioned on the second side member 54 of the seatback frame assembly50 at the upper engagement member 176 and then clipped into place usingthe resilient clip member 174 for securely mounting the trim member 172thereto. In the embodiment shown in FIG. 6H, the first actuator 170includes a coupling portion 170B and a handle portion 170A, wherein thecoupling portion 170B is coupled to the first end 72A of the first cable72, such that the first cable 72 travels with the first actuator 170between at-rest and actuated positions. In FIG. 6H, the first actuator170 is shown in an at-rest position. With reference to FIG. 6G, thefirst actuator 170 is shown in the actuated position, wherein the loopshaped handle portion 170A is contemplated to have been engaged by auser and lifted upwardly in the direction indicated by arrow 90 to movethe first actuator 170 from the at-rest position to the actuatedposition. In so doing, the first end 72A of cable 72 will move from afirst position (identified as 72A1) to a second position (identified as72A2). The first and second positions 72A1, 72A2 identify at-rest andactuated positions for the first end 72A of the first cable 72 when thefirst actuator 170 moves between at-rest and actuated positions as shownin FIGS. 6H and 6G.

Referring now to FIG. 7, the second cable 74 is shown having the secondend 74B coupled to a recliner mechanism 80 disposed on the seatbackframe 50. As noted above, the recliner mechanism 80 is a reclinermechanism known in the art and operable between locked and releasepositions, wherein the seatback frame 50 can move to the full forwardposition F (FIG. 1) when the recliner mechanism 80 is in the releaseposition. The recliner mechanism 80 moves from the locked position tothe release position as the second cable 74 moves upward in a directionindicated by arrow 180 to release the recliner mechanism 80. As notedabove, the second cable 74 is pulled as an output response to the secondactuator 120 as actuated by the first actuator 30 via first cable 72.Thus, in an overview sense, the first actuator 30 is coupled to a firstend 72A of first cable 72 as shown in FIG. 5B. The first cable 72includes a second end 72B which is coupled to the first mountingaperture 130A of second actuator 120 shown in FIG. 6A. First end 74A ofsecond cable 74 is coupled to mounting aperture 130B of second actuator120, as also shown in FIG. 6A. With further reference to FIG. 7, thesecond end 74B of second cable 74 is coupled to the recliner mechanism80 for moving the recliner mechanism 80 from a locked position to arelease position. As such, when the first actuator 30 moves to theactuated position (FIG. 5B), the second actuator 120 moves to theactuated position (FIG. 6B). Movement of the second actuator 120 to theactuated position shown in FIG. 6B pulls the second cable 74 in anupward direction as indicated by arrow 180 at the recliner mechanism 80to release the recliner mechanism 80, thereby allowing movement of theseatback frame 50 (and seatback 16) to a full forward position to betterprovide access to a rear seating option in a vehicle.

Referring now to FIG. 8A, the headrest assembly 20 of the vehicle seat10 shown in FIG. 1 is shown in an exploded view. In the exploded view ofFIG. 8A, the headrest assembly 20 is shown having a front panel 190having a base portion 22A and a support portion 24A. The headrestassembly 20 further includes a rear panel 192 having a base portion 22Band a support portion 24B. Together, the base portion 22A of the frontpanel 190 and the base portion 22B of the rear panel 192 cooperate todefine the base portion 22 of the headrest assembly 20 shown in FIG. 1.Similarly, the support portions 24A, 24B of the front and rear panels190, 192 cooperate to define the support portion 24 of the vehicle seat10 shown in FIG. 1. In assembly, the front and rear panels 190, 192couple to one another and further couple to a support member 200 that isconfigured to support the headrest assembly 20 from the seatback frame50 (FIG. 3), as further described below. In assembly, the headrest bun26 of the headrest assembly 20 is configured to be removeably coupled tothe support portion 24A of the front panel 190. The thoracic supportcushion 28 of the headrest assembly 20 is also configured to couple tothe base portion 22A of the front panel 190. The headrest bun 26 andthoracic support cushion 28 are shown coupled to the front panel 190 inthe embodiment shown in FIG. 1.

As further shown in FIG. 8A, the front panel 190 includes a front outersurface 190A. The front outer surface 190A includes a plurality ofmounting slots 194 which are configured to couple to clip members of thethoracic support cushion 28 as better shown in FIG. 8B. The base portion22A of the front panel 190 is a forwardly curved portion having a widththat is commensurate with a width of the seatback 16 shown in FIG. 1. Inthis way, the base portion 22A extends outwardly past the parameters ofthe support portion 24A. The forwardly curved configuration of the baseportion 22A provides a cradling effect for the neck and shoulders of avehicle occupant being supported by the headrest assembly 20. The baseportion 22A further includes mounting apertures 196B which are used tocouple the base portion 22A to the seatback frame 50 (FIG. 3) usingfasteners at mounting apertures 196B. Mounting apertures 196A aredisposed on the front panel 190 and used to couple the front panel 190to the rear panel 192 at reciprocal mounting features disposed on rearpanel 192, as further described below. The support portion 24A of thefront panel 190 includes a generally centrally disposed mounting surface198 that is generally inset from a frame 199 disposed therearound. Inthe embodiment shown in FIG. 8A, the mounting surface 198 includes aplurality of mounting apertures 202 disposed therethrough which areconfigured to receive fasteners 204 therethrough for removeably couplingthe headrest bun 26 to the front panel 190. The frame 199 substantiallysurrounds the mounting surface 198 and includes generally angledsidewalls, through which mounting apertures 206 are disposed and used tocouple the front panel 190 to the rear panel 192 in assembly. Theoutward extension of the frame 199 relative to the inset mountingsurface 198 creates a receiving cradle 210. As further described below,the headrest assembly 20 of the present invention is configured to havethe headrest bun 26 removeably mounted to the mounting surface 198 ofthe front panel 190, such that when a vehicle occupant is wearing ahelmet, a rear portion of the helmet may be received in the receivingcradle 210 defined by the outwardly extending frame 199 and insetmounting surface 198. The receiving cradle 210 is accessible when theheadrest bun 26 has been removed. The mounting surface 198 also servesas a rigid support surface for a rear portion of the helmet of vehicleoccupant when the headrest bun 26 has been removed. Mounting and removalof the headrest bun 26 is further described below with specificreference to FIGS. 8A-13D.

With further reference to FIG. 8A, the support member 200 is shownhaving first and second legs 212, 214 which are interconnected by anupper cross member 216. The support member 200 further includes firstand second support wings 220, 222 which are coupled to the first andsecond legs 212, 214, respectively. The first and second support wings220, 222 extend outwardly from the first and second legs 212, 214 andare further positioned in a forward direction to match the configurationof the forwardly curved base portion 22A of the front panel 190 to whichthe first and second support wings 220, 222 are coupled in assembly. Thefirst and second legs 212, 214 further include guide sleeves 224, 226 atends of the first and second legs 212, 214, wherein the guide sleeves224, 226 may be integrally formed with the first and second supportwings 220, 222, as further described below. The support member 200further includes attachment features 217A-217C which are used to couplethe front and rear panels 190, 192 to the support member 200 in assemblyas further described below.

As further shown in FIG. 8A, the rear panel 192 is shown from an innersurface 192B and includes a base portion 22B having first and secondforwardly curved arms 230, 232, which further include pass-through holes234, 236, which may be configured to receive straps for an over-shouldermulti-strap seat harness that may be used in conjunction with the highperformance vehicle seat 10 of the present concept. Like the front panel190, the support portion 24B of the rear panel 192 generally includes acentrally disposed mounting surface 238 having a frame 239 disposedtherearound. The mounting surface 238 includes a plurality of mountingapertures 242 disposed therethrough which are configured to receive thefasteners 204 for coupling the mounting surface 238 to the mountingsurface 198 of the front panel 190. The first and second arms 230, 232of the base portion 22B of the rear panel 192 are forwardly curved armswhich match the configuration of the first and second support wings 220,222 of the support member 200, as well as the forwardly curved baseportion 22A of the front panel 190.

Referring now to FIG. 8B, rear sides of the headrest bun 26 and thethoracic support cushion 28 are shown, wherein the headrest bun 26includes a mounting plate 250 disposed on the rear portion thereof. Themounting plate 250 includes mounting apertures 252 which are configuredto align with the mounting apertures 202 of the mounting surface 198 ofthe front panel 190, as well as mounting apertures 242 of the mountingsurface 238 of the rear panel 192. When the mounting apertures 252, 202and 242 of the headrest bun 26, the front panel 190 and the rear panel192, respectively, are aligned, fasteners 204 are used to couple theheadrest bun 26 to the front and rear panels 190, 192. As further shownin FIG. 8B, a plurality of clip members 254 are shown outwardlyextending from the thoracic support cushion 28 which are used to couplewith the mounting slots 194 disposed on the base portion 22A of thefront panel 190. In FIG. 8B, the front panel 190 is shown from a rear orinner surface 190B thereof. Similarly, the rear panel 192 is shown froma rear outer surface 192A thereof. The inner surfaces 190B and 192B ofthe front and rear panels 190, 192 include a number of coupling featuresthat are used to couple the front and rear panels 190, 192 to oneanother, as well as to the support member 200. The inner surfaces 190B,192B of the front and rear panels 190, 192 are further described belowwith specific reference to FIGS. 10A and 10B.

Referring now to FIGS. 9A and 9B, the support member 200 of the headrestassembly 20 is shown. As noted above, the support member 200 includesfirst and second legs 212, 214 which are interconnected by an uppercross member 216, such that the support member 200 has a generallydownwardly opening U-shaped configuration. The first and second legs212, 214 are angled to have outward and forward extending portions 212A,214A. These outwardly extending and forward portions 212A, 214A of thesupport member 200 further provide support for the receiving cradle 210by reinforcing the mounting surfaces 198, 238 and frames 199, 239 of thefront and rear panels 190, 192, respectively. As further shown in FIG.9A, the attachment features 217A-217C include coupling portions 260which couple the attachment features 217A-217C to the support member200. In the embodiment shown in FIGS. 9A and 9B, the support member 200is a generally contemplated to be a rigid metal tubular structure havinga rounded outer surface 200A, which may include a 12-13 mm diameter. Thecoupling portions 260 of the attachment features 217A-217C arecontemplated to be plastic composite structures which are overmolded tothe armature structure of the support member 200. As used herein, theterm “overmolded” and/or “overmolding” refers to a process by which onethermoplastic material is molded over another material(s) to form aunitary part. In an overmolding process of the present concept, a firstcomponent (or multiple components) are formed and placed in a mold.After positioning the first component in the mold, a second component isinjected into and molded in the mold that already contains the firstcomponent. In this way, the first and second components are adhered toeach other over at least a portion of a surface of the first component.The overmolding process of the present concept allows for the metalsupport member 200 and the plastic attachment features 217A-217C to forma unitary hybrid composite structure made of steel and plastic formounting the front and rear panels 190, 192 thereto. The first andsecond support wings 220, 222 are also plastic parts which areovermolded to the support member 200 as further described below.

As further shown in FIGS. 9A and 9B, attachment feature 217A is showndisposed on leg 212 of the support member 200, while attachment feature217C is shown disposed on leg 214 of the support member 200. Attachmentfeature 217B is shown disposed on the upper cross member 216 of thesupport member 200. It is contemplated that the attachment features217A-217C may be coupled to any portion of the support member 200 forproviding a loading surface and mounting feature for the front and rearpanels 190, 192 in assembly. As noted above, each of the attachmentfeatures 217A-217C include a coupling portion 260 which is overmolded tothe outer surface 200A to the support member 200. Each of the attachmentfeatures 217A-217C further includes a plurality of plates 262 thatoutwardly extend from the coupling portion 260. The plates 262 arespaced-apart to define the outwardly opening channels 264, 266therebetween. Specifically, the outwardly opening channels 264 open in aforward direction for receiving support ribs of the inner surface 190Bof the front panel 190. Similarly, outwardly opening channels 266 arerearwardly opening channels configured to receive support ribs of theinner surface 192A of the rear panel 192. In this way, the outwardlyopening channels 264, 266 defined by the spaced-apart plates 262 of theattachment features 217A-217C provide mounting and locating features forproperly positioning and mounting the front and rear panels 190, 192 tothe support member 200, such that the support member 200 can provide arigid frame structure for supporting the front and rear panels 190, 192.

As further shown in FIGS. 9A and 9B, the first and second support wings220, 222 are shown coupled to and extending outwardly from the first andsecond legs 212, 214 of the support member 200 and having a forwardlyangled pitch. Each of the support wings 220, 222 is coupled to thesupport member 200 at a coupling portion 270 which is contemplated to beovermolded to the first and second legs 212, 214. Each of these supportwings 220, 222 includes an upper arm 272, a lower arm 274, and an endportion 276 inner-connecting the upper and lower arms 272, 274.Together, the upper arm 272, lower arm 274, end portion 276, andcoupling portion 270 define pass-through holes 280A, 280B for the firstand second support wings 220, 222, respectively. With specific referenceto second support wing 222 in FIG. 9A, the second support wing 222includes a plurality of rearwardly extending plates 282 which arespaced-apart from one another to define a plurality of outwardly openingchannels 284, wherein the outwardly opening channels 284 are rearwardlyopening in configuration. The lower arm 274 is shown having plates 286extending upwardly therefrom in a spaced-apart manner along the lowerarm 274 to define outwardly opening channels 288. The outwardly openingchannels 288 are upwardly opening channels in configuration aspositioned on an upper portion of the lower arm 274. This sameconfiguration of plates 282, 286 and channels 284, 288 is shown on thefirst support wing 220 in FIG. 9B. The channels 284, 288 of the firstand second support wings 220, 222 are configured to receive support ribsof the front and rear panels 190, 192, as further described below.

As further shown in FIGS. 9A and 9B, the first and second guide sleeves224, 226 are integral parts that can be overmolded to end portions ofthe first and second legs 212, 214, respectively, and are contemplatedto be integral parts to the first and second support wing structures220, 222. In assembly, the guide sleeves 224, 226 are configured to bereceived in the receiving apertures 62, 64 of the upper cross member 56of the seatback frame 50 as shown in FIG. 3. In this way, the first andsecond guide sleeves 224, 226 can support the support member 200 in anupright and upwardly extending manner from the upper cross member 56 ofthe seatback frame 50.

Referring now to FIGS. 10A and 10B, the inner surfaces 190B, 192B of thefront and rear panels 190, 192 are shown. With specific reference toFIG. 10A, the inner surface 190B of the front panel 190 is shown havinga plurality of spaced-apart support ribs 300 disposed thereon.Specifically, the support ribs 300 are disposed around a periphery ofthe support portion 24A of the front panel 190. As noted above, thesupport portion 24A of the front panel 190 is generally defined by aninset mounting surface 198 that is substantially surrounded by anoutwardly extending frame 199. In the embodiment shown in FIG. 10A, theframe 199 includes first and second sides 199A, 199B and a top portion199C inner-connecting the first and second sides 199A, 199B. The supportribs 300 are disposed around the first and second sides 199A, 199B andthe top portion 199C to surround the outer portions of the mountingsurface 198. As disposed around the parameters of the frame 199, thesupport ribs 300 serve to rigidify the frame 199 and also serve asmating coupling features for the attachment features 217A-217C of thesupport member 200 best shown in FIGS. 9A, 9B. Specifically, the supportribs 300 of the front panel 190 are configured to be received in theoutwardly opening channels 264 of the support member 200 which open in aforward direction on a front side of the support member 200, as bestshown in FIG. 9A. With the support ribs 300 disposed on the sideportions 199A, 199B and the upper portion 199C of the frame 199, thesupport ribs 300 can attach to the outwardly opening channels 264 of theattachment features 217A-217C disposed on the first and second legs 212,214 and the upper cross portion 216 of the support member 200.

With specific reference to FIG. 10B, the inner surface 192B of the rearpanel 192 is shown having a plurality of spaced-apart support ribs 302disposed thereon. Specifically, the support ribs 302 are disposed arounda periphery of the support portion 24B of the rear panel 192. As notedabove, the support portion 24B of the rear panel 192 is generallydefined by a mounting surface 238 substantially surrounded by a frame239. In the embodiment shown in FIG. 10B, the frame 239 includes firstand second sides 239A, 239B and a top portion 239C inner-connecting thefirst and second sides 239A, 239B. The support ribs 302 are disposedaround the first and second sides 239A, 239B and the top portion 239C tosurround the outer portions of the mounting surface 298. As disposedaround the parameters of the frame 239, the support ribs 302 serve torigidify the frame 239 and also serve as mating coupling features forthe attachment features 217A-217C of the support member 200 best shownin FIGS. 9A, 9B. Specifically, the support ribs 302 of the rear panel192 are configured to be received in the outwardly opening channels 266of the support member 200 which open in a rearward direction on a rearside of the support member 200 as best shown in FIG. 9B. With thesupport ribs 302 disposed on the side portions 239A, 239B and the upperportion 239C of the frame 239, the support ribs 302 of the rear panel192 can attach to the outwardly opening channels 266 of the attachmentfeatures 217A-217C of the support member 200, while the support ribs 300of the front panel 190 attach to the outwardly opening channels 264 ofthe attachment features 217A-217C of the support member 200.

With further reference to FIG. 10A, the front panel 190 is shown havingfirst and second pass-through holes 304, 306 having perimeters 308, 310,respectively, disposed therearound. A plurality of support ribs 312, 314are shown outwardly extending from the perimeters 308, 310 of the firstand second pass-through holes 304, 306 of the front panel 190. Inassembly, the support ribs 312, 314 are configured to be received in theupwardly opening channels 288 of the first and second support wings 220,222 as shown in FIGS. 9A and 9B. In this way, the plurality of supportribs 312, 314 disposed around the perimeters 308, 310 of the first andsecond pass-through holes 304, 306 define support ribs positioned on thebase portion 22A of the front panel 190.

Referring again to FIG. 10B, the rear panel 192 is shown having firstand second pass-through holes 234, 236 having perimeters 316, 318,respectively, disposed therearound. A plurality of support ribs 320, 322are shown outwardly extending from the perimeters 316, 318 of the firstand second pass-through holes 234, 236 of the rear panel 192. Inassembly, the support ribs 320, 322 are configured to be received in therearwardly opening channels 284 of the first and second support wings220, 222 as shown in FIGS. 9A and 9B. In this way, the plurality ofsupport ribs 320, 322 disposed around the perimeters 316, 318 of thefirst and second pass-through holes 234, 236 define support ribspositioned on the base portion 22B of the rear panel 192.

In assembly, the first and second pass-through holes 304, 306 of thefront panel 190 (FIG. 10A) are configured to align with the first andsecond pass-through holes 234, 236 of the rear panel 192 (FIG. 10B). Thefirst and second pass-through holes 304, 306 and 234, 236 of the frontand rear panels 190, 192 are further configured to align with thepass-through holes of the 280A, 280B of the support member 200 (FIG.9A). Thus, the vehicle seat assembly 10 (FIG. 1) includes first andsecond pass-through holes disposed on the base portion 22 of theheadrest assembly 20 as shown in FIG. 1 when the component parts of theheadrest assembly 20 are coupled together. The pass-through holes areconfigured to provide a passage way for a multi-point harness havingover-the-shoulder restraining straps passing thru the first and secondpass-through holes.

The front panel 190 is configured to couple to the rear panel 192 atmounting apertures 206 of the front panel 190 which are configured toalign with mounting bosses 324 of the rear panel 192. Further, themounting apertures 196A of the front panel 190 disposed on the baseportion 22A thereof are configured to couple to mounting bosses 326 ofthe rear panel 192 which are disposed on the first and second arms 230,232 which define the base portion 22B of the rear panel 192. The abovenoted couplings can be made using fasteners extending though themounting apertures 206, 196A of the front panel 190 that are received inand coupled to the mounting bosses 324, 326 of the rear panel 192.Further, the above noted couplings can be made using a hot melttechnique, or using an adhesive to adhere the mounting bosses 324, 326of the rear panel 192 to the mounting apertures 206, 196A of the frontpanel 190. In this way, the front and rear panels 190, 192 couple to thesupport member 200, and further couple to one another at mountingapertures 206, 196A and mounting bosses 324, 326. The coupling of thefront and rear panels 190, 192 with the attachment features 217A-217C ofthe support member 200 at support ribs 300, 314, 312, 302, 320, 322 ofthe front and rear panels 190, 192 is contemplated to be retained usinga hot melt technique or an adhesive to adhere the front and rear panels190, 192 to the attachment features 217A-217C of the support member 200.As noted above, the front panel 190 also couples to the seatback frame50 at mounting apertures 196B. As shown in FIG. 10B, the rear panel 192includes a mounting structure 330 defined by a plurality of spaced-apartribs 332 to form a downwardly hook-shaped configuration which isconfigured to be received in the mounting aperture 57 disposed on theupper portion 56A of the seatback frame 50 as shown in FIG. 4B. Thisinterconnection of the front and rear panels 190, 192, the supportmember 200, and the seatback frame 50 provides for a rigid andsupporting configuration for the headrest assembly 20 in assembly asshown in the vehicle seat assembly 10 of FIGS. 1 and 2.

Referring now to FIG. 11A, a headrest assembly 20 is shown similar tothe headrest 20 shown in FIG. 8A. The headrest assembly 20 of FIG. 11Aincludes a number of engagement features for providing a headrest buncoupling system that allows for an end user to easily mount and removethe headrest bun 26 therefrom. Specifically, as shown in FIG. 11A, therear panel 192 includes a mounting surface 238 having a single mountingaperture 242 disposed therethrough. It is contemplated that multiplemounting apertures 242 may be used with the present concept, however,the embodiment shown in FIG. 11A will be described with a singlemounting aperture 242 disposed in the mounting surface 238 of the rearpanel 192. Mounting aperture 242 of the rear panel 192 is configured toalign with a mounting aperture 202 of the front panel 190. Mountingaperture 202 of the front panel 190 is also disposed on a mountingsurface 198 of the front panel 190. The mounting apertures 242 and 202are generally centrally located at lower portions of the mountingsurfaces 238, 198 of the rear and front panels 192, 190, respectively.As aligned with one another, the mounting apertures 242, 202 areconfigured to receive a retaining fastener 204 for retaining theheadrest bun 26 on the mounting surface 198 of the front panel 190, asfurther described below.

As further shown in FIG. 11A, the mounting surface 198 of the frontpanel 190 includes first and second receiving slots 340, 342 disposedtherethrough. The first and second receiving slots 340, 342 each includefirst and second ends 344, 346. As shown in FIG. 11A, the first ends 344are larger than the second ends 346, such that the first and secondreceiving slots 340, 342 generally define keyhole slots. As noted above,the mounting surface 198 of the front panel 190 is surrounded by anoutwardly extending frame 199 to define a receiving cradle 210. Thefirst and second receiving slots 340, 342 are disposed through themounting surface 198 for releasably coupling the headrest bun 26 to thefront panel 190, such that the headrest bun 26 can be releasablyreceived in the cradle 210. As noted above, the headrest bun 26 isconfigured to be removed from the front panel 190 in order to provideaccess to the receiving cradle 210 which is configured to receive a rearportion of a helmet worn by a vehicle occupant when the vehicle seat 10(FIG. 1) is used in a high-performance vehicle in particular conditions,wherein a vehicle occupant is required to, or chooses to, wear a helmet.In this way, the vehicle seat 10 is configurable between a comfortsetting having the headrest bun 26 coupled to the front panel 190 asshown in FIG. 1, and is also configurable to meet race-day conditions,wherein the headrest bun 26 is removed to provide access to thereceiving cradle 210.

Referring now to FIG. 11B, the headrest bun 26 is shown having themounting plate 250 disposed on a rear portion thereof. In the embodimentshown in FIG. 11B, the mounting plate 250 includes first and secondfastener members 350, 352 which are spaced-apart to align with thespaced-apart first and second receiving slots 340, 342 of the frontpanel 190. The first and second fastener members 350, 352 each include ahead portion 354 and a shaft portion 356. As shown in FIG. 11B, the headportions 354 have a first width, while the shaft portions 356 havesecond width. The first width of the head portions 354 is larger thanthe second width of the shaft portions 356. Given the above notedconfiguration of the first and second fastener members 350, 352, thefirst and second fastener members 350, 352 are configured to be receivedin and retained in the first and second receiving slots 340, 342 of thefront panel 190. In order to couple the fastener members 350, 352 to thereceiving slots 340, 342, the head portions 354 of the first and secondfastener members 350, 352 are received through the larger first ends 344of the receiving slots 340, 342. In the embodiment shown in FIGS. 11Aand 11B, the first and second receiving slots 340, 342 are verticallydisposed, such that the headrest bun 26 is moved downward after the headportions 354, of the first and second fastener members 350, 352 arereceived through the larger first ends 344 of the first and secondreceiving slots 340, 342. As the headrest bun 26 moves downward alongthe first and second receiving slots 340, 342, the shaft portions 356 ofthe first and second fastener members 350, 352 are received in thesecond end 346 of the first and second receiving slots 340, 342. Thewidth of the head portions 354 of the first and second fastener members350, 352 is generally larger than the width of the second ends 346 ofthe first and second receiving slots 340, 342, such that the headportions 354 of the first and second fastener members 350, 352 areretained within the first and second receiving slots 340, 342 at thesecond ends 346 thereof.

As further shown in FIG. 11B, the mounting plate 250 of the headrest bun26 includes an outwardly extending mounting boss 251 which is configuredto align with the mounting apertures 202, 242 of the front and rearpanels 190, 192, respectively. In this way, the retaining fastener 204can be received through the mounting apertures 202, 242 of the front andrear panels 190, 192 and couple to the mounting boss 251 extendingrearwardly from the mounting plate 250 of the headrest bun 26. In thisway, the retaining fastener 204 retains the headrest bun 26 fromvertical movement along the retaining slots 340, 342. As noted above,the releasability of the headrest bun 26 provides access to thereceiving cradle 210 of the front panel 190 for the receiving of a rearportion of a helmet worn by a vehicle occupant. The mounting surface 198of the front panel 190 is an inset mounting surface, as the frame 199 isan outwardly extending frame that substantially surrounds the mountingsurface 198. In this way, the mounting surface 198 and the frame 199cooperate to define the receiving cradle 210. As shown in FIGS. 11A and11B, the headrest bun 26 includes a front cushioned member 27 whichoutwardly extends from the mounting plate 250. The size and outwardextension of the cushioned member 27 would create an uncomfortableposition for a vehicle occupant seated in the vehicle seat 10 when thevehicle occupant is wearing a helmet. As such, with the headrest bun 26removed from the front panel 190, the receiving cradle 210 is configuredto receive a rear portion of a helmet worn by a vehicle occupant thatgenerally occupies a similar amount of space previously occupied by theheadrest bun 26. In this way, a vehicle occupant can have a similarposition when seated in the vehicle seat 10 with the headrest bun 26 inplace, or with the headrest bun 26 removed therefrom when the vehicleoccupant is wearing a helmet.

Referring now to FIG. 12A, a receiving block 370 is shown, wherein thereceiving block 370 includes a body portion 372 having a receiving slot374 disposed therein. The receiving slot 374 includes an open first end376 disposed on a front surface 378 of the body portion 372 of thereceiving block 370. The receiving slot 374 further includes a secondend 380 which is wider than the first end 376 for retaining an interlockmember, as further described below. The second end 380 of the receivingslot 374 includes a front surface 382 having first and second receivingapertures 384, 386 disposed therein. The first and second receivingapertures 384, 386 are configured to receive first and second detentengagement features 390, 392. Each of the detent engagement features390, 392 includes a body portion 394 having a retractable engagementmember 396 extending outwardly therefrom. The retractable engagementmember 396 is contemplated to be biased toward an outwardly extendingposition as shown in FIG. 12A and retractable against a biasingmechanism disposed within the body portion 394 for allowing theinsertion and removal of an interlock member, as further describedbelow.

Referring now to FIG. 12B, the headrest bun 26 is shown having aninterlock member 400 extending outwardly from the mounting plate 250 ofthe headrest bun 26. The interlock member 400 includes a base portion402 and a plate portion 404, wherein the base portion 402 has a widththat is less than the width of the plate portion 404. As configured inthe manner illustrated in FIG. 12B, the interlock member 400 isconfigured to be received in the receiving slot 374 of the receivingblock 370 shown in FIG. 12A. Specifically, the plate member 404 isconfigured to be disposed and retained in the second end 380 of thereceiving slot 374, while the base portion 402 of the interlock member400 is configured to be received in the first end 376 of the receivingslot 374. In this way, first and second sides 376A, 376B of the firstend 376 of the receiving slot 374 are configured to retain first andsecond sides 404A, 404B of the plate portion 404 of the interlock member400 when the interlock member 400 is received in the receiving slot 374.Further, a lower end 404C of the plate portion 404 of the interlockmember 400 is retained by a lower wall 376C of the first end 376 of thereceiving slot 374, wherein the lower end 376C interconnects the firstand second sides 376A and 376B as shown in FIG. 12A.

The interlock member 400 further includes an outer surface 406 havingfirst and second inset detent features 408, 410. The first and secondinset detent features 408, 410 are generally provided as dimples whichinwardly extend into the plate portion 404 of the interlock member 400.The inset detent features 408, 410 may include a variety ofconfigurations that are properly suited to receive the retractableengagement members 396 of the first and second detent engagementfeatures 390, 392 of the receiving block 370.

Referring now to FIG. 12C, the front panel 190 is shown coupled to therear panel 192 to define the base portion 22 and support portion 24 ofthe headrest assembly 20. The receiving block 370 is shown received onthe mounting surface 198 of the front panel 190, wherein the mountingsurface 198 is an inset mounting surface due to the outwardly extendingframe 199 surrounding the mounting surface 198 to define the receivingcradle 210. The headrest bun 26 is shown exploded away from the supportportion 24 with the interlock member 400 shown in phantom on a rearsurface of the headrest bun 26. The interlock member 400 is shownaligned with the receiving slot 374 of the receiving block 370 to bereceived therein. The detent engagement features 390, 392 of thereceiving block 370 are further shown aligned with the detent receivingfeatures 408, 410 of the interlock member 400, such that the retractableengagement members 396 of the first and second of the retractable detentengagement features 390, 392 may be received in the inset detentfeatures 408, 410, respectively.

Referring now to FIG. 12D, the headrest bun 26 is shown received in thereceiving cradle 210 and coupled to the mounting surface 190 by aninterconnection of the interlock member 400 and receiving slot 374 andreceiving block 370. In this configuration, the retractable detentengagement features 390, 392 are configured to have the engagementmembers 396 received in the inset detent features 408, 410 of theinterlock member 400. Having a ball-shaped configuration, the engagementmembers 396 are configured to be plunged inwardly into the body portions394 (FIG. 12A) when connected by the plate portion 404 of the interlockmember 400, and again extend to the extended position, as biasedthereto, when the engagement members 396 align with the inset detentfeatures 408, 410 of the interlock member 400. This engagement of theengagement members 396 and the inset detent features 408, 410 retainsthe headrest assembly 26 against upward vertical movement. It is furthercontemplated that the headrest assembly 20 shown in FIG. 12D may alsoinclude a retaining fastener, such as retaining fastener 204 shown inFIGS. 11A and 11B, to further restrict vertical movement of the headrestbun 26 as received in the receiving cradle 210.

Referring now to FIG. 13A, another embodiment of a headrest assembly 418is shown, wherein front and rear panels 420, 422 are configured to becoupled to support member 200 as well as coupled to one another. Thesupport member 200 is contemplated to have a similar configuration tothe support member 200 as shown in FIGS. 11A and 11B. The front and rearpanels 420, 422 include configurations which generally follow theparameters of the support member 200, such that the front and rearpanels 420, 422 generally cooperate to define first and second sides424, 426 which are interconnected by an upper portion 428. The first andsecond sides 424, 426 and upper portion 428 cooperate to define areceiving cradle 430 configured to receive a rear portion of a helmetworn by a vehicle occupant. The receiving cradle 430 includes a webmember 432 disposed therein having three legs 434, 436, and 438 whichinterconnect to the first and second sides 424, 426 and the upperportion 428, respectively. Each leg 434, 436, and 438 includes areceiving aperture 440 disposed therethrough for receiving fasteners forcoupling to a headrest assembly 450, as shown in FIG. 13B.

Referring now to FIG. 13B, the headrest assembly 450 is shown having amounting plate 452 disposed on a rear portion and a front cushionedmember 454. The mounting plate 452 includes a plurality of outwardlyextending mounting bosses 456 which are configured to align with thereceiving apertures 440 of the web member 432. In this way, fastenerspassing through the receiving apertures 440 of the web member 432 cancouple to the outwardly extending mounting bosses 456 of the headrestassembly 450 for coupling the headrest assembly 450 to the web member432 in a releasable manner.

In the embodiment shown in FIGS. 13C and 13D, the headrest assembly 450is shown mounted to the web member 432 in a removable manner viafasteners contemplated to be inset within receiving apertures 440.

It will be understood by one having ordinary skill in the art thatconstruction of the described disclosure and other components is notlimited to any specific material. Other exemplary embodiments of thedisclosure disclosed herein may be formed from a wide variety ofmaterials, unless described otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the disclosure as shown in the exemplary embodiments isillustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connector or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present disclosure. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present disclosure, and further it is to beunderstood that such concepts are intended to be covered by thefollowing claims unless these claims by their language expressly stateotherwise.

We claim:
 1. A headrest assembly, comprising: a support member havingfirst and second legs interconnected by an upper cross member; a frontpanel coupled to a front side of the support member; a rear panelcoupled to a rear side of the support member, wherein the front and rearpanels define a support portion having first and second sidesinterconnected by an upper portion; a web member having a plurality oflegs interconnecting the first and second sides and upper portion of thesupport portion, wherein one or more legs of the plurality of legs ofthe web member includes a receiving aperture disposed therethrough forreceiving a fastener; and a headrest bun releasably coupled to the webmember by the fastener.
 2. The headrest assembly of claim 1, whereineach leg of the plurality of legs of the web member includes a receivingaperture disposed therethrough for receiving fasteners for releasablycoupling the headrest bun to the web member.
 3. The headrest assembly ofclaim 2, wherein the headrest bun includes a mounting plate.
 4. Theheadrest assembly of claim 3, wherein the mounting plate includes aplurality of outwardly extending mounting bosses which align with themounting apertures disposed on each leg of the plurality of legs of theweb member.
 5. The headrest assembly of claim 4, wherein the fastenersare received in the outwardly extending mounting bosses of the mountingplate to releasably couple the headrest bun to the web member.
 6. Theheadrest assembly of claim 3, wherein the headrest bun includes a frontcushioned member disposed on a front portion of the mounting plate.
 7. Aheadrest assembly, comprising: front and rear panels coupled to oneanother around front and rear sides of a support member, the front andrear panels defining a support portion having first and second sidesinterconnected by an upper portion; a web member having a plurality oflegs interconnecting the first and second sides and upper portion of thesupport portion, wherein the web member includes a plurality ofreceiving apertures disposed therethrough, and further wherein each legof the plurality of legs of the web member includes one or morereceiving apertures of the plurality of receiving apertures; and aheadrest bun releasably coupled to a front side of the web member. 8.The headrest assembly of claim 7, wherein the headrest bun includes amounting plate.
 9. The headrest assembly of claim 8, wherein themounting plate includes a plurality of rearwardly extending mountingbosses.
 10. The headrest assembly of claim 9, including: fastenersreceived through the receiving apertures and coupled to the rearwardlyextending mounting bosses of the headrest bun to releasably couple theheadrest bun to the web member.
 11. The headrest assembly of claim 8,wherein the headrest bun includes a front cushioned member disposed on afront portion of the mounting plate.
 12. A headrest assembly,comprising: a support member having first and second legs interconnectedby an upper cross member; a web member having first, second and thirdlegs interconnecting the first and second legs and upper cross member ofthe support member, wherein the web member includes first and secondreceiving apertures; and a headrest bun releasably coupled to a frontside of the web member at the at least one receiving aperture thereof,wherein the headrest bun includes a mounting plate having a cushionedmember disposed on a front side thereof, and further wherein theheadrest bun includes first and second mounting bosses extendingoutwardly from a rear side of the mounting plate, the first and secondmounting bosses received in the first and second receiving apertures ofthe web member, respectively.
 13. The headrest assembly of claim 12,including: first and second fasteners received through the first andsecond receiving apertures disposed through the first and second legs ofthe web member, wherein the first and second fasteners are coupled tothe first and second mounting bosses of the mounting plate to releasablycouple the headrest bun to the web member.